Modular packaging system

ABSTRACT

A packaging system includes a container with a bottom wall, a first end wall connecting to the bottom wall, a second end wall opposed to the first end wall and connecting to the bottom wall, at least a portion of a first side wall connecting between the first and second end walls, at least a portion of a second side wall opposed to the first side wall and connecting between the first and second end walls, and a plurality of corner walls. At least one corner wall connects the first end wall to the portion of a first side wall.

BACKGROUND 1. Field

The field of the present disclosure relates generally to packaging containers and, more particularly, to a container formed from multiple blanks to provide a reinforced container with enhanced strength.

2. Description of Related Art

Corrugated fiberboard containers or boxes are known to come in a variety of shapes and constructions. At least some known containers that are used to transport and/or store products may be stacked on top of each other when the products are being transported or stored. The side walls of the containers on the lower layers of the stack are configured to support a weight of the containers on the upper layers of the stack. Products within the lower container may then be required to support the weight of the upper layers. Typical containers to achieve this support are generally three-piece “bliss” containers that include two side panels and a body panel, which can include the other two sides and top and bottom.

The conventional techniques have been considered satisfactory for their intended purpose. However, there is an ever present need for improved systems and methods for shipping, storing and displaying product. This disclosure provides a solution for this need.

SUMMARY

A packaging system includes a container with a bottom wall, a first end wall connecting to the bottom wall, a second end wall opposed to the first end wall and connecting to the bottom wall, at least a portion of a first side wall connecting between the first and second end walls, at least a portion of a second side wall opposed to the first side wall and connecting between the first and second end walls, and a plurality of corner walls. At least one corner wall connects the first end wall to the portion of a first side wall.

In some embodiments, a top wall is opposed to the bottom wall where the top wall and the bottom wall are formed from identical panels. The first and second end walls can be formed from end panels. Each corner wall can be formed from a respective corner panel foldably connected to at least one of the end panels. At least a portion of each first side wall can be formed from a respective side flap extending from at least one of the top wall, the bottom wall, or one of the corner panels. At least a portion of each first side wall can be formed from at least two opposing side flaps. Each opposing side flap can extend from one of the corner panels.

In some embodiments, each opposing side flap includes an end edge. The end edges of the opposing side flaps can be spaced apart from one another. The end walls can include a v-notch portion. The top wall and at least a portion of the first end wall can be configured and adapted to be removed from the bottom wall and at least a portion of the second end wall to prepare the container for retail display.

In accordance with another aspect, a packaging blank system includes a first blank having a bottom panel, with a plurality of side flaps and a plurality of end flaps foldably connected to the bottom panel and at least one corner flap foldably connected to at least one of the side or end flaps. The bottom panel, end flaps, side flaps and the at least one corner flap are configured to be formed into a tray. The packaging blank system includes a second blank having an end panel, a pair of corner panels each foldably connected to opposite sides of the end panel, and a pair of side flaps, each side flap foldably connected to a respective one of the corner panels. The end panel, the pair of corner panels and the pair of side flaps are configured to form a container insert.

In some embodiments, an outer surface of the second blank is configured and adapted to be adhered to an inner surface of the first blank to form a half of a container. The at least one corner flap can include a plurality of corner flaps. Each corner flap can include a respective support flap foldably attached thereto. Each side flap of the second blank includes a tapered portion. The first blank can be made from a first material and the second blank can be made from a second material. The first and second materials can be different from another and/or have more or less plies than one another.

In some embodiments, the end panel of the second blank includes four portions foldably connected to one another. A first and a second of the portions can be foldably connected to respective corner panels. A third and a fourth of the portions can be foldably connected between the first and second portions. The third and fourth portions can be adjacent to one another and configured to be folded at oblique angles with respect to the first and second portions.

The packaging blank system can include a third blank having a top panel, with a plurality of flaps foldably connected to the top panel. The top panel and flaps can be configured to be formed into a container lid with a top wall, a first end wall connected to the top wall, a second end wall opposed to the first end wall and connected to the top wall, a first side wall connected to the top wall, a second side wall opposed to the first side wall and connected to the top wall, and a plurality of corner walls. At least one corner wall can be connected to the portion of the first side wall. The packaging blank system can include a fourth blank having an end panel, a pair of corner panels each foldably connected to opposite sides of the end panel, and a pair of side flaps. Each side flap can be foldably connected to a respective one of the corner panels. The end panel, the pair of corner panels and the pair of side flaps can be configured to form a container insert. An outer surface of the fourth blank can be configured and adapted to be adhered to an inner surface of the third blank to form a half of a container.

In some embodiments, the end panel of the fourth blank includes four portions foldably connected to one another. A first and a second of the portions can be foldably connected to respective corner panels. A third and a fourth of the portions can be foldably connected between the first and second portions. The third and fourth portions can be adjacent to one another and configured to be folded at oblique angles with respect to the first and second portions. Each side flap of the fourth blank can include a tapered portion.

These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description of the preferred embodiments taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to certain figures, wherein:

FIG. 1 is a perspective view of a container constructed in accordance with the present disclosure;

FIG. 2 is a plan view of a blank for forming a top and/or bottom portion of the container of FIG. 1;

FIG. 3 is a plan view of a blank for forming a side portion of the container of FIG. 1;

FIGS. 4A-4F are perspective views of the container of FIG. 1, showing the container during the folding and assembly process;

FIG. 5 is a plan view of a blank for forming a top and/or bottom portion of another embodiment of a container constructed in accordance with the present disclosure; and

FIGS. 6A-6F are perspective views of the container of FIG. 5, showing the container during the folding and assembly process;

FIG. 7 is a plan view of another embodiment of a blank for forming a side portion of a container constructed in accordance with the present disclosure;

FIGS. 8A-8B are perspective views of the container using the blank of FIG. 7, showing the container during the assembly process;

FIG. 9 is a plan view of another embodiment of a blank for forming a side portion of a container constructed in accordance with the present disclosure;

FIGS. 10A-10D are perspective views of the container using the blank of FIG. 9, showing the container during the folding and assembly process;

FIG. 11 is a perspective view of another embodiment of a container constructed in accordance with the present disclosure, where the container is formed using the blank of FIG. 2 and the blank of FIG. 3, but does not include a top portion;

FIG. 12 is a perspective view of another embodiment of a container constructed in accordance with the present disclosure, where the container is formed using the blank of FIG. 2 and the blank of FIG. 5, but does not include a top portion; and

FIG. 13 is a perspective view of another embodiment of a container constructed in accordance with the present disclosure, where the container is formed using the blank of FIG. 5 and an embodiment of the blank of FIG. 2 with extended side panels such that the sides are enclosed.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, a perspective view of an embodiment of a modular packaging system in accordance with the disclosure is shown in FIG. 1 and is designated generally by reference character 101. Other embodiments of systems in accordance with the disclosure, or aspects thereof, are provided in FIGS. 2-13, as will be described. The systems and methods described herein can be used to provide modular containers formed from corrugated fiberboard, e.g. cardboard blanks, that allow for a variety of different configurations that allow for use of different materials and/or thicknesses for a given portion of the container. Because of the variety of configurations, container 101 can be used in a variety of commercial areas, e.g. industrial, retail, and club store.

As shown in FIG. 1, packaging system includes a four piece container 101 having a bottom wall 102, a top wall 104 opposed to the bottom wall 102, a first end wall 106 connecting between the bottom wall 102 and the top wall 104, a second end wall 108 opposed to the first end wall 106 and connecting between the bottom wall 102 and the top wall 104. At least a portion of a first side wall 110 is connecting between the bottom wall 102 and the top wall 104. At least a portion of a second side wall 112 (shown in FIG. 4F) is opposed to the first end wall 106 and is connecting between the bottom wall 102 and top wall 104. The container 101 includes a plurality of corner walls 114. One of the corner walls 114 connects the first end wall 106 to the first side wall 110. A second of the corner walls 114 connects the second end wall 108 to the first side wall 110. A third of the corner walls 114 connects the first end wall 106 the second side wall 112. A fourth of the corner walls 114 connects the second end wall 108 to the second side wall 112.

With continued reference to FIG. 1, the top wall 104 and the bottom wall 102 are formed from identical top and bottom panels 116. The first and second end walls 106 and 108 are each formed from a combination of end flaps 132 and end panels 232. Each corner wall 114 is formed from a combination of corner flaps 134 and corner panel 234. Each side wall 110 is formed from a combination of side flaps, some of which extend downward or upward from respective top and bottom walls 104 and 102, others of which extend laterally from the corner walls 114. For example, each side wall 110 includes two side flaps 124 and two side flaps 224. Each side flap 224 includes an end edge 230. The end edges 230 of opposing side flaps 224 on a given side wall (e.g. side wall 110 or side wall 112) are spaced apart from one another. The top wall 104 and at least a portion of the first end wall 106 can be configured and adapted to be removed from the bottom wall 102 and at least a portion of the second end wall 108 to prepare the container for retail display, as described in more detail in FIGS. 4A-4F.

As shown in FIG. 2, a packaging blank system for forming container 101 includes a blank 100 having a top/bottom panel 116, with a plurality of side flaps 124 are foldably connected to the top/bottom panel about respective fold lines 125. A plurality of end flaps 132 are foldably connected to the top/bottom panel 116 about respective fold lines 131. Corner flaps 134 are foldably connected to each of the side flaps 124 about respective fold lines 127. The top/bottom 116 panel, end flaps 132, side flaps 124 and corner flaps 134 are configured to be formed into a tray 103, shown in FIGS. 4A-4D. End flaps 132 and side flaps 124 have the same height h. In order to form a container 101 (with both a top tray 103 and a bottom tray 103) two blanks 100 can be used to form two trays 103 (shown in FIG. 4E, described below).

With reference now to FIG. 3, the packaging blank system to form container 101 includes a blank 200 having an end panel 232, a pair of corner panels 234 each foldably connected to opposite sides of end panel 232 about respective fold lines 225, and a pair of side flaps 224. Each side flap 224 is foldably connected to a respective one of the corner panels 234 about a respective fold line 227. End panel 232, corner panels 234 and side flaps 224 are configured to form a container insert 205, shown in FIG. 4D.

As shown in FIGS. 4A-4F, an outer surface 220 of the second blank 200 is configured and adapted to be adhered to an inner surface 121 of first blank 100, then the panels of blank 100 and blank 200 are folded about their respective fold lines to form a half (e.g. half 101 a or 101 b) of a container 101. It is contemplated that the folding and assembly of blanks 100 and 200 into a given half (e.g. 101 a or 101 b) can be achieved using mandrel forming technology. Adhesive 122, shown in FIG. 2, is applied to the inner surface 121 of blank 100 during the container forming process in order to secure the blank 200 to blank 100. It is contemplated that product (not shown) can be loaded onto tray 103 prior to completion of container 101. For example, product can be loaded into tray 103 in the step shown in FIG. 4D for example. Container 101 is formed with a reduced body structure due to the shallow height h of trays 103, resulting in a reduction in material required as compared with traditional full-wrap containers, thereby reducing costs. During shipping, container 101 still maintains the desired strength due to container inserts 205 (e.g. “bliss” sides), which provide the desired structural support needed during stacking of multiple containers. Blank 200 that forms container inserts 205 can be formed from a thicker or stiffer material (e.g. a thicker or stiffer cardboard material) than that of blank 100. Once container 101 is ready for display, the top half 101 a of the container can be removed, resulting in a retail-ready leave-behind portion 101 b. Removal of the top half 101 a can be made possible by choosing the proper strength for and type of adhesive 122. The leave-behind on shelf has a front shallow tray lip or the flap 132 lays down flat such that product is viewable.

As shown in FIG. 5, another embodiment of a blank 300, e.g. a first blank, is shown. Blank 300 is the same as blank 100, except that blank 300 includes support flaps 336, described below. Blank 300 includes a top/bottom panel 316, with a plurality of side flaps 324 and a plurality of end flaps 332 foldably connected to the top/bottom panel 316 about respective fold lines 325. Corner flaps 334 are foldably connected to each of the side flaps 324 about respective fold lines 327. Each corner flap 334 includes a respective support flap 336 foldably attached thereto about a respective fold line 351. The top/bottom 316 panel, end flaps 332, side flaps 324, corner flaps 334 and support flaps 336 are configured to be formed into a tray 303, shown in FIGS. 6A-6F. Support flaps 336 provide increased strength for the ends of tray 303. In order to form a container 301 (with both a top tray 303 and a bottom tray 303) two blanks 300 can be used to form two trays 303 (shown in FIG. 4E, described below).

As shown in FIGS. 6A-6F, the top/bottom 316 panel, end flaps 332, side flaps 324 and corner flaps 334 of blank 300 are configured to be folded about their respective fold lines to be formed into a tray 303. As shown in FIG. 6E, support flaps 336 can be folded inside of their respective end flaps 332 (bottom tray of FIG. 6E) or outside of their respective end flaps (top tray 303 of FIG. 6E). Container insert 205 is then used in conjunction with tray 303 and folded about its respective fold lines to form a container 301. Container 301 is the same as container 101 in that in includes the same number of sides, e.g a bottom wall 302, a top wall 304 opposed to the bottom wall 302, a first end wall 306 connecting between the bottom wall 302 and the top wall 304, a second end wall 308 opposed to the first end wall 306 and connecting between the bottom wall 302 and the top wall 304, a first side wall 310 and a second side wall 312, and corner walls 314, where each of the corner walls 314 connect between one of the end walls and one of the side panels. Similar to container 101, an outer surface 220 of the blank 200 is configured and adapted to be adhered to an inner surface 321 of the blank 300 to form a half (e.g. half 301 a or 301 b) of container 301. Folding and assembly can similarly be performed using mandrel technology and product can be loaded in a similar manner as described above with respect to container 101. Adhesive 322 (shown in FIG. 5) is applied to the inner surface 321 of blank 300 during the container forming process in order to secure the outer surface 220 of blank 200 to inner surface 321 of blank 300. As shown in FIG. 12, in some embodiments, instead of having two trays 303, only a bottom tray can be used to form an open top container. Additionally, as shown in FIG. 13, trays 303 formed from blanks 300 can be used with a container insert 505, which is the same as container insert 205 except instead of having a gap between edges 230 of two opposing inserts 205, edges of insert 505 abut those of an opposing insert 505 to form a fully enclosed container 501. Inserts 505 can similarly be used with tray 103 as well. Container 301 is similarly formed with a reduced body structure due to the shallow height h of trays 303, resulting in the same advantages as describe above. The shipping advantages described above and those associated with using inserts 205 are also present for container 301. Once container 301 is ready for display, the top half 301 a of the container can be removed and the leave-behind can be used for display of product, in the same way as that described above relative to container 101.

As shown in FIG. 7, the packaging blank system includes a blank 400, e.g. a second blank, having end panels 432. Blank 400 can be used instead of two of blanks 200 in any of the trays described herein. Each end panel 432 has a pair of corner panels 434 each foldably connected to opposite sides of their respective end panel 432. Blank 400 includes tapered side flaps 424. Each tapered side flap 424 is foldably connected to a respective one of the corner panels 234. The end panel 232, the corner panels 234 and the side flaps 224 are configured to form a container insert 205. In the embodiment of FIG. 7, blank 400 includes a cut line 433 that separates two form container inserts 401 a and 401 b such that both inserts 405 a and 405 b that would, for example, be used in conjunction with a tray, e.g. tray 103 or tray 303, are formed in a single blank 400.

As shown in FIGS. 8A-8B, trays 303 formed from blanks 300 are used in conjunction with blank 400. Blank 400 is folded to form two container inserts 405 a and 405 b and nested within and adhered to trays 303 to form container 401. Container 401 is the same as container 101 in that in includes the same number of sides, e.g a bottom wall 402, a top wall 404 opposed to the bottom wall 402, a first end wall 406 connecting between the bottom wall 402 and the top wall 404, a second end wall 408 opposed to the first end wall 406 and connecting between the bottom wall 402 and the top wall 404, a first side wall 410 and a second side wall 412, and corner walls 414, where each of the corner walls 414 connect between one of the end walls and one of the side panels.

With continued reference to FIGS. 8A-8B, similar to container 301, an outer surface 420 of the blank 400 is configured and adapted to be adhered to an inner surface 321 of the blank 300 to form a half (e.g. half 401 a or 401 b) of a container 401. Adhesive 322 (shown in FIG. 5) is applied to the inner surface 321 of blank 300 during the container forming process in order to secure the outer surface 420 of blank 400 to inner surface 321 of blank 300. Because of the tapered side flaps 424, when blank 400 is formed into container inserts 405 a and 405 b, the sides 410 and 412 will form a ‘stadium style’ retail-ready container. To display product, the top half 401 a can be removed from 401 b in a similar manner to that described above for containers 101 and 301.

With reference now to FIG. 9, in accordance with another embodiment of the container insert, a blank 500 includes an end panel 532 of that includes four portions 532 a-532 d foldably connected to one another about fold lines 531 a-531 c. A first portion 532 a and a second portion 532 d are foldably connected to respective corner panels 534 about respective fold lines 525. Each corner panel 534 is foldably connected to a respective side flap 524 about a respective fold line 527. A third portion 532 b and a fourth portion 532 c of end panel 532 are foldably connected between the first and second portions 532 a and 532 d about respective fold line 531 b. The third and fourth portions 532 b and 532 c are adjacent to one another and configured to be folded at oblique angles with respect to the first and second portions 532 a and 532 d to form a v-notched container insert 505. V-Notched multi angled end panel 532 can be utilized with trays 103 or 303 where additional stacking strength is required.

As shown in FIGS. 10A-10D, the top/bottom 316 panel, end flaps 332, side flaps 324 and corner flaps 334 are configured to be formed into a tray 303. Two container inserts 505 are then used in conjunction with two trays 303 to form container 501. Similar to container 101, an outer surface 520 of the blank 500 (specifically corner panels 534 and end portions 532 a and 532) are configured and adapted to be adhered to an inner surface 321 of the blank 300 to form a half (e.g. half 501 a or 501 b) of a container 501. To form the other half, another insert blank 500 and another tray blank 300 are used. Adhesive 322 (shown in FIG. 5) is applied to the inner surface 321 of blank 300 during the container forming process in order to secure the outer surface 520 of blank 500 to inner surface 521 of blank 300. When combining halves 501 a and 501 b together to form container 501, an inner surface of tray 303 of half 501 b may be adhered to an outer surface of insert 505 of half 501 a or insert 505 of half 501 a may simply be nested within tray 303 of half 501 b. The same can be said for the connection between insert 505 of half 501 b and the tray 303 of half 501 a. Container 501 has the same advantages with respect to shipping and display as those described above with container 101, but also provides increased strength due to the v-notch 509.

The methods and systems of the present disclosure, as described above and shown in the drawings, provide for a modular packaging system that can be readily assembled to suit strength needs and retail-ready options. While the apparatus and methods of the subject disclosure have been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the scope of the subject disclosure. 

What is claimed is:
 1. A packaging system comprising: a container with a bottom wall, a first end wall connecting to the bottom wall, a second end wall opposed to the first end wall and connecting to the bottom wall, at least a portion of a first side wall connecting between the first and second end walls, at least a portion of a second side wall opposed to the first side wall and connecting between the first and second end walls, and a plurality of corner walls, wherein at least one corner wall connects the first end wall to the portion of a first side wall.
 2. The packaging system as recited in claim 1, further comprising a top wall opposed to the bottom wall, wherein the top wall and the bottom wall are formed from identical panels.
 3. The packaging system as recited in claim 2, wherein the top wall and at least a portion of the first end wall are configured and adapted to be removed from the bottom wall and at least a portion of the second end wall to prepare the container for retail display.
 4. The packaging system as recited in claim 1, wherein the first and second end walls are formed from end panels.
 5. The packaging system as recited in claim 4, wherein each corner wall is formed from a respective corner panel foldably connected to at least one of the end panels.
 6. The packaging system as recited in claim 1, wherein at least a portion of each side wall is formed from at least two opposing side flaps, each opposing side flap extending from a respective corner panel forming, at least in part, one of the corner walls.
 7. The packaging system as recited in claim 5, wherein each opposing side flap includes an end edge, wherein the end edges of the opposing side flaps are spaced apart from one another.
 8. The packaging system as recited in claim 1, wherein the end walls include a v-notch portion.
 9. A packaging blank system comprising: a first blank having a bottom panel, with a plurality of side flaps and a plurality of end flaps foldably connected to the bottom panel and at least one corner flap foldably connected to at least one of the side or end flaps, wherein the bottom panel, end flaps, side flaps and the at least one corner flap are configured to be formed into a tray; and a second blank having an end panel, a pair of corner panels each foldably connected to opposite sides of the end panel, and a pair of side flaps, each side flap foldably connected to a respective one of the corner panels, wherein the end panel, the pair of corner panels and the pair of side flaps are configured to form a container insert.
 10. The packaging blank system as recited in claim 9, wherein an outer surface of the second blank is configured and adapted to be adhered to an inner surface of the first blank to form a half of a container.
 11. The packaging blank system as recited in claim 9, wherein the at least one corner flap includes a plurality of corner flaps, wherein each corner flap includes a respective support flap foldably attached thereto.
 12. The packaging blank system as recited in claim 9, wherein the end panel of the second blank includes four portions foldably connected to one another, wherein a first and a second of the portions are foldably connected to respective corner panels, wherein a third and a fourth of the portions are foldably connected between the first and second portions, wherein the third and fourth portions are adjacent to one another and configured to be folded at oblique angles with respect to the first and second portions.
 13. The packaging blank system as recited in claim 9, wherein each side flap of the second blank includes a tapered portion.
 14. The packaging blank system as recited in claim 9, further comprising a third blank having a top panel, with a plurality of flaps foldably connected to the top panel, wherein the top panel and flaps are configured to be formed into a container lid.
 15. The packaging blank system as recited in claim 14, further comprising a fourth blank having an end panel, a pair of corner panels each foldably connected to opposite sides of the end panel, and a pair of side flaps, each side flap foldably connected to a respective one of the corner panels, wherein the end panel, the pair of corner panels and the pair of side flaps are configured to form a second container insert.
 16. The packaging blank system as recited in claim 15, wherein an outer surface of the fourth blank is configured and adapted to be adhered to an inner surface of the third blank to form a half of a container.
 17. The packaging blank system as recited in claim 15, wherein the end panel of the fourth blank includes four portions foldably connected to one another, wherein a first and a second of the portions are foldably connected to respective corner panels, wherein a third and a fourth of the portions are foldably connected between the first and second portions, wherein the third and fourth portions are adjacent to one another and configured to be folded at oblique angles with respect to the first and second portions.
 18. The packaging blank system as recited in claim 15, wherein each side flap of the fourth blank includes a tapered portion. 